Abstract: An electrochemical cell that cycles lithium ions includes a positive electrode that includes a positive electroactive material, a negative electrode that includes a negative electroactive material, and a free-standing separating layer disposed between the positive electrode and the negative electrode. The free-standing separating layer includes a gel membrane that includes a polymer host and a liquid electrolyte and an integrated structural component disposed within the gel membrane. The integrated structural component may be selected from the group consisting of: a plurality of solid-state electrolyte particles, a nonwoven material, and a combination thereof.

Abstract: An anode-free electrochemical cell that cycles lithium ions includes a positive electrode assembly having a positive current collector and a positive electroactive material layer, a negative current collector that includes a surface configured to receive a negative electroactive material after one or more formation cycles of the anode-free electrochemical cell, and a separating layer disposed between the positive electroactive material layer and the surface of the negative current collector. The separating layer includes an electrolyte that includes greater than or equal to about 20 wt. % to less than or equal to about 99.5 wt. % of a concentrated electrolyte having a lithium salt concentration greater than or equal to about 2 M to less than or equal to about 6 M, and greater than or equal to about 0.5 wt. % to less than or equal to about 80 wt. % of an ionic liquid.

Abstract: A modular bipolar solid-state battery includes T solid-state battery modules, where T is an integer greater than one. Each of the T solid-state battery modules includes an enclosure, a first terminal arranged on a first side of the enclosure, a second terminal arranged on a second side of the enclosure opposite to the first side of the enclosure, and N solid-state battery cells arranged and interconnected in the enclosure, where N is an integer greater than one. The T solid-state battery modules are connected in at least one of series and parallel. A positive terminal of the modular bipolar solid-state battery is connected to at least one of the T solid-state battery modules. A negative terminal of the modular bipolar solid-state battery is connected to at least another one of the T solid-state battery modules.

Abstract: A battery cell includes a cathode electrode comprising a cathode coating arranged on a cathode current collector and a separator. A dual function interlayer comprising capacitor material and lithium-ion source material is arranged one of between the cathode coating and the cathode current collector and between the cathode coating and the separator. An anode electrode is arranged adjacent to the separator and comprising an anode coating arranged on an anode current collector.

Abstract: A method for testing a sample of a battery cell includes arranging the sample of the battery cell in a sample pan of a test crucible; arranging a spacer on the sample of the battery cell; sealing the sample pan; and performing differential scanning calorimetry (DSC) testing of the sample.

Abstract: A method for manufacturing a gel membrane for a battery cell includes supplying a first substrate to a first roller; heating a gel membrane solution in a tank, wherein the gel membrane solution includes a polymer and a liquid electrolyte comprising one or more lithium salts; arranging a slot die within a predetermined distance of the first substrate located on the first roller; pumping the gel membrane solution into an inlet of the slot die; depositing a gel membrane layer from an outlet of the slot die onto the first substrate supported by the first roller; and cooling the gel membrane layer on the first substrate.

Abstract: A bipolar battery cell includes a bipolar electrode including a bipolar current collector and a cathode electrode arranged on one side of the bipolar current collector. The cathode electrode includes cathode active material for exchanging lithium ions, a first solid electrolyte, and first polytetrafluoroethylene (PTFE) fibrils. An anode electrode is arranged on an opposite side of the bipolar current collector, wherein the anode electrode includes anode active material for exchanging lithium ions, a second solid electrolyte, and second PTFE fibrils.

Abstract: An anode electrode includes a current collector and a first anode layer arranged on the current collector and comprising first anode active material. A first pre-lithiation layer is arranged on the first anode layer. A second anode layer arranged on the first pre-lithiation layer and comprising second anode active material.

Abstract: A battery cell includes an anode electrode comprising a first current collector. Anode active material is arranged on a first surface of the first current collector and is configured to exchange lithium ions. The anode active material comprises silicon. Empty spaces are formed in the anode active material in a predetermined pattern. A solid electrolyte layer is arranged adjacent to the anode electrode. A cathode electrode comprises a second current collector and cathode active material configured to exchange lithium ions and arranged adjacent to the solid electrolyte layer.

Abstract: An electrochemical cell includes a first electrode that includes a first current collector and a first electroactive material layer disposed on or near the first current collector, a second electrode that includes a second current collector and a second electroactive material layer disposed on or near the second current collector, and a separating layer disposed between the first electroactive material layer and the second electroactive material layer. The second electroactive material layer includes a plurality of hierarchical silicon columns, each of the hierarchical silicon columns has a longest dimension perpendicular to a major axis of the second current collector. The second electroactive material layer also includes a carbonaceous network that at least partially fills interstices defined between hierarchical silicon columns of the plurality of hierarchical silicon columns. The carbonaceous network includes linked carbon atoms that define a plurality of pores.

Abstract: A hybrid electrochemical device including at least two electrically connected solid-state electrochemical cells is provided. Each electrochemical cell includes a first outer electrode having a first current collector and a first electroactive layer, a second outer electrode having a second current collector and a second electroactive layer, and one or more intervening electrodes disposed between the electroactive layers. At least one of the intervening electrodes includes one or more capacitor additives. The first outer electrode is electrically connected to at least one of the intervening electrodes in a first electrical configuration. The second outer electrode is electrically connected to at least one of the intervening electrodes in a second electrical configuration. The at least two electrochemical cells are electrically connected in a third electrical configuration.

Abstract: A battery includes positive and negative current collectors and a plurality of bipolar electrodes arranged in a stack between the positive and negative current collectors. The positive and negative current collectors and the stack of the plurality of bipolar electrodes are folded in an S-shape.

Abstract: In various aspects, the present disclosure provides solvent-free methods of making a solid-state electrode active layer for a solid-state electrode in an electrochemical cell that cycles lithium ions, by using a plurality of solid polymeric binder particles capable of fibrillation with porous fibrillation particles with a first shear force to at least partially fibrillate the solid polymeric binder particles to form a polymeric binder mixture. The disclosure also contemplates a current collector and a porous active layer disposed thereon. The porous active layer includes a fibrous polymeric network having a plurality of solid particles distributed therein. The solid particles may include electroactive material particles, solid-state electrolyte particles, and porous fibrillation particles.

Abstract: A bipolar battery includes N battery cores each comprising a cathode electrode, an anode electrode, and a separator, where N is an integer greater than one. N?1 bipolar plates include a first layer made of a first material, a second layer made of a second material, a center portion, and first and second sides extending transversely relative to the center portion. A battery enclosure including a cover and a lower portion including sides defining a cavity. The N?1 bipolar plates are arranged in the cavity between adjacent ones of the N battery cores and the N battery cores are connected in series by the N?1 bipolar plates. The first and second sides of the N?1 bipolar plates are one of inserted into “L”-shaped slots in the sides of the lower portion, and molded into the sides of the lower portion.

Abstract: A battery cell includes a continuous anode electrode comprising an anode current collector. A plurality of individual cathode electrodes include a cathode current collector, cathode active material arranged on opposite sides of the cathode current collector, and a first sulfide electrolyte layer arranged on the cathode active material. The continuous anode electrode is arranged in a zig-zag pattern and the plurality of individual cathode electrodes are arranged between adjacent alternating portions of the continuous anode electrode.

Abstract: A bipolar solid-state battery includes N solid-state battery cells. Each of the N solid-state battery cells includes M solid-state cores each comprising a first current collector, cathode active material, a separator, anode active material, and a second current collector, where N and M are integers greater than one. The M solid-state cores are connected in parallel by connecting the first current collectors of the M solid-state cores in each of the N solid-state battery cells together and by connecting the second current collectors of the M solid-state cores in each of the N solid-state battery cells together. N?1 clad plates including a first side made of a first material and a second side made of a second material. The N?1 clad plates are arranged between adjacent ones of the N solid-state battery cells and the N solid-state battery cells are connected in series by the N?1 clad plates.

Abstract: A bipolar battery cell includes a stack including N current collectors, M anode electrodes, S separators, and C cathode electrodes, where N, M, S and C are integers greater than one. A first positioning member is arranged on one side of the stack and includes a first planar portion and a first slot in the first planar portion. A first one of the C current collectors extends through the first slot in the first planar portion and is folded. The first positioning member further includes a first rail portion and a second rail portion. The first rail portion and the second rail portion extend from the first planar portion. A first external tab is arranged between the first rail portion and the second rail portion and connected to the first one of the C current collectors.

Abstract: An electrode assembly for an electrochemical cell that cycles lithium ions is provided. The electrode assembly includes one or more electroactive material layers including a plurality of electroactive material particles and a plurality of binder material fibers dispersed with the electroactive material particles. At least one electroactive material particle of the plurality may have a first protective layer coated thereon, and at least one binder material fiber of the plurality may have a second protective layer coated thereon. The first and second protective layers may be the same or different. The binder material fibers can include polytetrafluoroethylene (PTFE).

Abstract: An electrochemical cell that includes a first electrode, a second electrode, and an electrolyte layer that is disposed between the first electrode and the second electrode is provided. The electrolyte layer includes a porous scaffold having a porosity greater than or equal to about 50 vol. % to less than or equal to about 90 vol. %, and a solution-processable solid-state electrolyte that at least partially fills the pores of the porous scaffold. The porous scaffold is defined by a plurality of fibers having an average diameter greater than or equal to about 0.01 micrometer to less than or equal to about 10 micrometers and an average length greater than or equal to about 1 micrometer to less than or equal to about 20 micrometers. The solution-processable solid-state electrolyte includes is selected from the group consisting of: sulfide-based solid-state particles, halide-based solid-state particles, hydride-based solid-state particles, and combinations thereof.

Abstract: The present disclosure provides an electrochemical cell that cycles lithium ions. The electrochemical cell includes a first electrode, a second electrode, a separator physically separating the first and second electrodes, a solid-state interlayer disposed between the separator and the first electrode, and a liquid electrolyte disposed in each of the first electrode, the second electrode, the separator, and the solid-state interlayer. The solid-state interlayer includes a plurality of solid-state electrolyte particles. The solid-state interlayer covers greater than or equal to about 85% of a total surface area of the surface of the first electrode.